Faucet including a molded waterway assembly

ABSTRACT

A faucet including a molded waterway assembly having a plurality of tubes overmolded within a valve interface member.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/848,737, filed Aug. 2, 2010, which is a continuation of U.S. patentapplication Ser. No. 11/700,634, filed Jan. 31, 2007, now U.S. Pat. No.7,766,043, which claims the benefit of U.S. Provisional Application Ser.No. 60/809,033, filed May 26, 2006, the disclosures of which areexpressly incorporated by reference herein.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates generally to plumbing fixtures and, moreparticularly, to a faucet including a molded waterway assembly.

Single handle faucets typically include mixing valves that control theflow of both hot and cold water to a delivery spout. These faucets havefound wide acceptance and are commonly constructed such that a handle orknob is movable in distinct directions to adjust the temperature (i.e.,the mix of hot and cold water) and the flow rate of water.

Conventional mixing valves typically include a machined brass body andassociated brass fittings. The brass body usually includes a hot waterinlet, a cold water inlet, and a mixed water outlet. An adjustable valveelement, typically either a mixing ball or a slidable plate, ismanipulated by a handle to control the aforementioned temperature andflow rate of water. In conventional faucets, copper tubes are usuallybrazed to the inlets and the outlet(s) of the valve body and toassociated fittings. Following the brazing operation, an etching orbright dip operation is typically performed to clean the metal surfacesof contaminants.

It may be appreciated that such conventional mixing valves have certaindisadvantages. For example, the cost of copper tubing and the additionalassembly cost associated with the brazing and bright dipping operationsmay be significant. The bright dipping operation may also result in theundesirable deposit of metal on the valve body. As such, it is knownthat the use of plastic materials for waterways may reduce cost,eliminate metal contact, and provide protection against acidic and otheraggressive water conditions. The use of non-metallic materials inplumbing fixtures is significant given the growing concern about thequality of potable water. The U.S. Environmental Protection Agency, NSFInternational (National Sanitary Foundation) and other health-relatedorganizations are actively seeking to reduce the metal content (i.e.,copper and lead) in water.

Previous plastic faucets have often attempted to use plastic in a methodsimilar to brass, i.e., as both a structural component and a waterconducting mechanism. This has caused some issues because the yieldstrength and stiffness of most plastics are not similar to theproperties of brass. This may result in the need to use higher gradematerials that can be difficult to process. Alternatively, materialsless suitable for structural applications may be used in the interest ofcost and long term durability.

According to an illustrative embodiment of the present disclosure, afluid delivery device includes a waterway assembly having a first inletfluid transport component formed of a polymer and with opposing firstand second ends, and an outlet fluid transport component formed of apolymer and with opposing first and second ends. The waterway assemblyfurther includes a base formed of a polymer and having an upper surfaceand a lower surface and being overmolded around the first end of thefirst inlet fluid transport component and the first end of the outletfluid transport component. A valve assembly includes a first inlet portin fluid communication with the first inlet fluid transport component,and an outlet port in fluid communication with the outlet fluidtransport component. The valve assembly further includes a lower surfacefacing the upper surface of the base and sealingly engaged with thebase. The valve assembly further includes a movable valve memberconfigured to control the flow of water from the first inlet port to theoutlet port.

According to a further illustrative embodiment of the presentdisclosure, a faucet includes a holder, and a waterway assemblyincluding a base supported by the holder. A hot water inlet tubularmember includes a first end fluidly coupled to the base and a second endconfigured to be fluidly coupled to a hot water supply. A cold waterinlet tubular member includes a first end fluidly coupled to the baseand a second end configured to be fluidly coupled to a cold watersupply. An outlet tubular member includes a first end fluidly coupled tothe base and a second end. A valve assembly includes a hot water inletport in fluid communication with the hot water inlet tubular member, anda cold water inlet port in fluid communication with the cold watertubular member. The valve assembly further includes an outlet port influid communication with the outlet tubular member, and a lower surfacefacing an upper surface of the base and sealingly couple with the base.The valve assembly also includes a movable valve member configured tocontrol the flow of water from the inlet ports to the outlet port. Alocking member is operably coupled to the valve assembly and isconfigured to secure the valve assembly to the waterway assembly.

According to a further illustrative embodiment of the presentdisclosure, a fluid delivery device includes a valve assembly having alower surface and a first locating element supported by the lowersurface. The fluid delivery device further includes a waterway assemblyhaving a first fluid transport component having opposing first andsecond ends, and a second fluid transport component having opposingfirst and second ends. A base includes an upper surface and a lowersurface and is overmolded around the first end of the first fluidtransport component and the first end of the second fluid transportcomponent. The waterway assembly further includes a second locatingelement supported by upper surface of the base and is configured tocooperate with the first locating element of the valve assembly tofacilitate proper orientation of the valve assembly relative to thewaterway assembly.

According to another illustrative embodiment of the present disclosure,a faucet includes a valve assembly, and a waterway assembly including afirst inlet fluid transport component formed of a non-metallic materialand having opposing first and second ends, and an outlet fluid transportcomponent formed of a non-metallic material and having opposing firstand second ends. The waterway assembly further includes a base formed ofan non-metallic material and having an upper surface and a lowersurface, the base being fluidly coupled to the first end of the firstfluid inlet transport component, the first end of the outlet fluidtransport component, and the valve assembly. An upper housing is formedof a non-metallic material and includes a spout having an outlet fluidlycoupled to the outlet fluid transport component, and a channel toreceive the outlet fluid transport component.

According to a further illustrative embodiment of the presentdisclosure, a waterway assembly includes a plurality of flexible tubularmembers formed of a polymer and having opposing first and second ends.The waterway assembly further includes a base formed of a polymer andovermolded around the first end to the plurality of tubular members.

According to yet another illustrative embodiment of the presentdisclosure, a waterway assembly includes a base including a plurality ofopenings. A plurality of tubular members formed of a cross-linkedpolymer includes opposing first and second ends, the first ends of theplurality of tubular members being received within the plurality ofopenings of the base.

According to a further illustrative embodiment of the presentdisclosure, a fluid delivery device includes a flow directing member,and a molded waterway fluidly coupled to the flow directing member. Themolded waterway includes a base having an inlet opening and an outletopening, and a flexible tubular member fluidly coupled to the inletopening. A fluid passageway extends from the inlet opening, through theflow directing member and out of the outlet opening wherein the fluidtravels in a first direction through the inlet opening and in a seconddirection, different from the first direction, through the outletopening.

According to another illustrative embodiment of the present disclosure,a base for a waterway assembly includes an upper surface, a lowersurface, a first inlet opening in fluid communication with the uppersurface, and an outlet opening in fluid communication with the uppersurface and positioned in spaced relation to the inlet opening. The baseis formed of a cross-linked polymer.

According to a further illustrative embodiment of the presentdisclosure, a waterway assembly includes a plurality of flexible tubularmembers formed of a polymer and having opposing first and second ends. Avalve interface member is formed of a polymer and overmolded around thefirst ends of the plurality of tubular members. The valve interfacemember includes a first surface, a second surface, a plurality ofopenings extending into the first surface and in fluid communicationwith the plurality of tubular members, a seat defined by the firstsurface and extending around the plurality of openings and configured toseal with a valve assembly to provide fluid communication between theplurality of openings and the valve assembly.

According to another illustrative embodiment of the present disclosure,a waterway assembly includes a base having a first surface, a secondsurface, a plurality of openings extending from the first surface to thesecond surface, and a seat defined by the first surface and configuredto sealingly interface with a valve assembly. A plurality of tubularmembers are formed of a cross-linked polymer and include opposing firstand second ends, the first ends of the plurality of tubular membersbeing received within the plurality of openings of the base andextending from the second surface. A plurality of fluid couplings aresupported by the second ends of the plurality of tubular members.

According to a further illustrative embodiment of the presentdisclosure, a valve interface member for a waterway assembly includes anupper surface, a lower surface, a first inlet opening extending into theupper surface, and an outlet opening extending into the upper surfaceand positioned in spaced relation to the inlet opening. A first flowdirecting channel extends into the upper surface, extends outwardly fromthe first inlet opening, and is in fluid communication with the firstinlet opening. A second flow directing channel extends into the uppersurface, extends outwardly from the outlet opening, and is in fluidcommunication with the outlet opening. A valve assembly seat issupported by the upper surface and extends around the first flowdirecting channel and the second flow directing channel, wherein thevalve interface member is formed of a cross-linked polymer.

Additional features and advantages of the present invention will becomeapparent to those skilled in the art upon consideration of the followingdetailed description of the illustrative embodiment exemplifying thebest mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the drawings particularly refers to theaccompanying figures in which:

FIG. 1A is a perspective view of an illustrative embodiment faucet ofthe present disclosure mounted to a sink deck and fluidly coupled to hotand cold water supply lines;

FIG. 1B is a perspective view similar to FIG. 1A, showing anotherillustrative fluid coupling to hot and cold water supply lines;

FIG. 1C is a perspective view similar to FIG. 1A, showing a furtherillustrative coupling to hot and cold water supply lines;

FIG. 2 is a perspective view of the faucet of FIG. 1;

FIG. 3 is a perspective view similar to FIG. 2, with the escutcheonremoved to show the molded waterway assembly, the holder, and the valveassembly;

FIG. 4 is a perspective view similar to FIG. 3, with the undercoverremoved to reveal additional details of the molded waterway assembly;

FIG. 5 is an exploded perspective view, with a partial cut-away, of thefaucet of FIG. 2;

FIG. 6 is a partial exploded perspective view of the faucet of FIG. 2,showing the escutcheon, the bonnet, the guide ring, and the securingsleeve;

FIG. 7 is a diagrammatic view of an illustrative embodiment faucetshowing a molded waterway assembly coupled to a valve assembly;

FIG. 8 is a cross-sectional view taken along line 8-8 of FIG. 2;

FIG. 9 is a detailed cross-sectional view of FIG. 8;

FIG. 10 is a partial exploded perspective view of the faucet of FIG. 2,showing the interface between the molded waterway assembly and the valvebody;

FIG. 11 is a top plan view of the base of the molded waterway assembly;

FIG. 12 is a bottom plan view of the base of molded waterway assembly;

FIG. 13 is a diagrammatic cross-sectional view showing anotherillustrative fluid coupling arrangement for the waterway assembly;

FIG. 14 is a diagrammatic cross-sectional view similar to FIG. 13,showing a further illustrative fluid coupling for the waterway assembly;

FIG. 15 is a side elevational view, in partial cross-section, of afurther illustrative embodiment faucet of the present disclosure;

FIG. 16 is a partial exploded perspective view of the faucet of FIG. 15;

FIG. 17 is a detailed view of the cross-section of FIG. 15;

FIG. 18 is a perspective view showing the molded waterway assembly ofthe faucet of FIG. 15 supported by the sink deck;

FIG. 19 is a partial perspective view of the molded waterway assembly ofFIG. 18;

FIG. 20 is an exploded perspective view of the molded waterway assemblyof FIG. 19;

FIG. 21 is a partial exploded perspective view of the faucet of FIG. 15,showing the interface between the valve body and the molded waterwayconnection;

FIG. 22 is a top plan view of the base of the molded waterway assembly;

FIG. 23 is a bottom plan view of the base of the molded waterwayassembly;

FIG. 24 is a diagrammatic view showing fluid flow in an illustrativewaterway assembly;

FIG. 25 is a diagrammatic view showing fluid flow in anotherillustrative waterway assembly; and

FIG. 26 is a diagrammatic view showing fluid flow in a furtherillustrative waterway assembly.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to beexhaustive or to limit the invention to precise forms disclosed. Rather,the embodiments selected for description have been chosen to enable oneskilled in the art to practice the invention. Although the disclosure isdescribed in connection with water, it should be understood thatadditional types of fluids may be used.

Referring initially to FIG. 1A, an illustrative embodiment faucet 10 isshown mounted to a sink or mounting deck 12 above a sink basin 14. Thefaucet 10 is fluidly coupled to hot and cold water supplies or sources16 and 18 through conventional stops 20 and 22, respectively. Hot andcold water risers 24 and 26 may fluidly couple the stops 20 and 22 tohot and cold water inlet fluid transport components, or tubes 28 and 30,respectively. While FIG. 1 illustrates hot and cold water risers 24 and26 coupled to inlet tubes 28 and 30 through fluid couplings 32 and 34,it should be appreciated that the inlet tubes 28 and 30 may extenduninterrupted from the faucet 10 to the stops 20 and 22 through fluidcouplings 36 and 38, as shown in FIG. 1B. Additionally, FIG. 1C shows anillustrative embodiment where inlet tubes 28 and 30 are coupled behindthe wall 40 to the plumbing system of the building or house.

Referring further to FIGS. 2-6, the faucet 10 includes a holder 42configured to be secured to the sink deck 12. The holder 42 includes apair of downwardly extending legs 44 and 46, illustratively comprisinghollow tubes having external threads 48 and 49, respectively. Securingmembers, illustratively nuts 50 and 51 are threadably received bythreads 48 and 49 of legs 44 and 46. The nuts 50 and 51 are configuredto secure the holder 42 to the sink deck 12. Supports 52 and 54 arecoupled to the upper ends of legs 44 and 46 and are connected by abridge member 56. The bridge member 56, in turn, supports a stand 58 inspaced relation above the supports 52 and 54.

With further reference to FIG. 5, the stand 58 illustratively includes acylindrical outer wall 59 supporting a plurality of external threads 60.An upper end of the wall 59 supports a platform 62 surrounding alongitudinal opening 64. In one illustrative embodiment, the holder 42is molded from a polymer, such as a long-fiber reinforced thermoplastic(LFRT) exhibiting high dimensional stability and strong mechanicalproperties. One such LFRT is Celstran® available from Ticona ofFlorence, Ky. However, it should be noted that the holder 42 may beformed of other suitable materials, such as stainless steel or brass.

With reference to FIGS. 4, 5, and 7, a molded waterway assembly 70 issupported by the stand 58 of holder 42. The molded waterway assembly 70illustratively includes a valve interface member or base 72 in the formof a puck or disk having a hot water inlet opening 74, a cold waterinlet opening 76, and an outlet opening 78, all extending between upperand lower surfaces 80 and 82 (FIG. 10). The hot water inlet tube 28, thecold water inlet tube 30, and an outlet tube 66 are fluidly coupled tothe openings 74, 76, and 78, respectively, in the base 72. As detailedherein, the tubes 28, 30, and 66 are illustratively formed of a flexiblenon-metallic material, such as a polymer.

In the illustrative embodiment, the tubes 28, 30, 66 and the base 72 areformed of compatible materials, such as polymers, and illustratively ofcross-linkable materials. As such, the waterway assembly 70 isillustratively electrically non-conductive. As used within thisdisclosure, a cross-linkable material illustratively includesthermoplastics and mixtures of thermoplastics and thermosets. In oneillustrative embodiment, the tubes 28, 30, 66 and the base 72 are formedof a polyethylene which is subsequently cross-linked to formcross-linked polyethylene (PEX). However, it should be appreciated thatother polymers may be substituted therefor. For example, the waterwayassembly 70 may be formed of any polyethylene (PE)(such as raisedtemperature resistant polyethylene (PE-RT)), of polypropylene (PP)(suchas polypropylene random (PPR)), or of polybutylene (PB). It is furtherenvisioned that the waterway assembly 70 could be formed of cross-linkedpolyvinyl chloride (PVCX) using silane free radical initiators, ofcross-linked polyurethane, or of cross-linked propylene (XLPP) usingperoxide or silane free radical initiators.

With reference to FIGS. 9, 10, and 12, the upper ends 84 of tubes 28,30, and 66 are positioned within the openings 74, 76, and 78 of the base72. Each opening 74, 76, and 78 includes a counterbore 74 a, 76 a, and78 a extending upwardly from the lower surface 82 and defining a stopsurface 75 which cooperates with the upper ends 84 of the tubes 28, 30,and 66, respectively. In the illustrative embodiment, the base 72 isovermolded around the upper ends 84 of the tubes 28, 30, and 66. Moreparticularly, the base 72 is formed of a polymer which is molded overthe previously formed tubes 28, 30, and 66, in the manner detailedherein. The overmold base 72 partially melts the upper ends 84 of thetubes, forming couplings or bonds 86 a, 86 b, 86 c between material ofthe base 72 and material of the tubes 28, 30, and 66 (showndiagrammatically in FIG. 7). To facilitate the molding process, theopenings 74, 76, and 78, and thus tubes 28, 30, and 66, areillustratively aligned along a common center axis 79 (FIG. 11). Flowdirecting channels 109, 111, and 113 are formed within upper surface 90of the base 72 and are configured to facilitate fluid flow throughopenings 74, 76, and 78, respectively (FIGS. 10 and 11).

As shown in FIGS. 9 and 12, a support or reinforcing boss 110illustratively extends downwardly from the lower surface 82 of the base72 and surrounds the openings 74, 76, and 78. The boss 110 providesadditional support to the tubes 28, 30, and 66 coupled to the base 72.

In the illustrative embodiment detailed herein, the base 72 is formed ofpolyethylene which has been overmolded around the tubes 28, 30, and 66and subsequently cross-linked. It should be noted that reinforcingmembers, such as glass fibers, may be provided within the polyethyleneof the base 72. While a polymer, such as cross-linkable polyethylene, isthe illustrative material for the base 72, in certain embodiments othermaterials may be substituted therefore, such as brass or copper.Additionally, the tubes 28, 30, and 66 may be fluidly coupled to thebase 72 in a variety of manners other than through overmolding, such asultrasonic welding or heat staking.

With reference now to FIGS. 13 and 14, illustrative alternative meansfor coupling the tubes 28, 30, and 66 are shown. For example, in FIG.13, the upper ends 84 of tubes 28, 30, and 66 include an enlargedportion 134 configured to be received within cooperating counterbores135 formed within base 72. As may be appreciated, each enlarged portion135 is retained intermediate a lip 136 formed within counterbore 135 ofthe base 72 and the lower surface 102 of the valve assembly 100. Theenlarged portion 135 may illustratively be formed integral with eachtube 28, 30, 66, or as a separate component, such as an overmold. Asshown in the further illustrative embodiment of FIG. 14, the upper ends84 of the tubes 28, 30, and 66 may include external threads 137 whichthreadably engage internal threads 139 formed within base 72.

As detailed herein, the base 72 of the waterway assembly 70 isillustratively secured to the tubes through overmolding. The basicprinciple of overmolding plumbing connections on the tubes is wellknown. Exemplary overmolds are shown in U.S. Pat. No. 5,895,695, U.S.Pat. No. 6,082,780, U.S. Pat. No. 6,287,501, and U.S. Pat. No. 6,902,210each listing William W. Rowley as an inventor, the disclosures of whichare all expressly incorporated by reference herein.

In the present method, the tubes 28, 30, and 66 are illustrativelypositioned within a mold (not shown) wherein pins or mandrels slide intoeach respective tube end 84 to prevent collapsing thereof during theinjection molding process. The mold receives the parallel aligned endsof the tubes 28, 30, and 66 and then receives a flowable polymer,illustratively polyethylene, which forms the appropriate base 72. Asfurther detailed herein, the upper ends 84 of the tubes 28, 30, 66 arealigned along a common axis 79 to facilitate opening and closing ofportions of the mold. After the polymer sufficiently hardens, the moldis opened to release the base 72 and tubes 28, 30, and 66. Throughovermolding, the end 84 of each tube 28, 30, and 66 partially melts andbonds with the overmolded material of the base 72 through couplings 86a, 86 b, and 86 c. This makes a substantially monolithic waterwayassembly 70.

As is known, polyethylene is flexible, or semi-rigid, and may becross-linked to form PEX. Cross-linking polyethylene couples theindividual molecule chains together and prevents splitting. The curingor cross-linking process may use any one of several differenttechnologies to form, for example, PEX-A, PEX-B or PEX-C. PEX-A isformed by using peroxide to cross-link polyethylene. More particularly,PEX-A is formed of a polyethylene having incorporated therein peroxide.Upon heating the peroxide polyethylene above the decompositiontemperature of the peroxide, “free” radicals are produced to initiatethe cross-linking process. PEX-B is formed by using silane to cross-linkpolyethylene. PEX-B is formed by using silane-grafted polyethylene whichis then “moisture-cured” by exposure to heat and water, also known assauna curing. PEX-C is formed of polyethylene which is cross-linked bybombarding it with electromagnetic (gamma) or high energy electron(beta) radiation.

By overmolding, it is possible to obtain a material to material bond,thereby providing a substantially leak-proof coupling between the tubes28, 30, and 66 and the base 72. The resulting overmolded waterwayassembly 70 is then cross-linked by means known in the art, e.g.,peroxide cross-linking, silane cross-linking, radiation cross-linking,etc. More particularly, and as detailed above, cross-linking can beperformed by a silane process or a peroxide process, or combinationsthereof, wherein cross-linking is completed in a hot bath. Each processhas a cross-linking catalyst that causes the polymer to crosslink whencertain temperature and pressure and/or humidity are used. In theillustrative embodiment, the waterway assembly (i.e., waterway assembly70) is passed under a radiation unit and the exposure causescross-linking. While illustratively the final product 70 iscross-linked, in certain circumstances it might be appropriate tocross-link individual components 28, 30, 66, and 72. In a furtherillustrative embodiment, the material for the base 72 may be partiallycross-linked prior to overmolding, followed by further cross-linkingafter coupling to the tubes 28, 30, and 66.

With reference to FIG. 2, the second ends 92 of each inlet tube 28 and30 illustratively includes a fluid coupling 94, which may definecouplings 32 and 34 shown in FIG. 1. Illustratively, each fluid coupling94 includes an overmolded coupler 96 and cooperating internally threadednut 98. Additional details regarding illustrative overmolded fluidcouplings is provided in U.S. Pat. Nos. 5,895,695 and 6,287,501, thedisclosures of which are expressly incorporated by reference herein.

In one illustrative embodiment, the tubes 28, 30, and 66 may includecertain additional features, such as corrugated walls for improvedflexibility, as detailed in U.S. Patent Application Publication No. US2008/0178957, published Jul. 31, 2008, entitled “TUBE ASSEMBLY,” thedisclosure of which is expressly incorporated by reference herein.

With reference to FIGS. 5, 9, and 10, a valve assembly 100 is supportedby the base 72 of the molded waterway assembly 70. More particularly, alower surface 102 of the valve assembly 100 sealingly engages a seal,illustratively a silicone gasket 103 received intermediate the base 72and the valve assembly 100. The gasket 103 is received within a channel104 formed within lower surface 102 of the valve assembly 100 and sealsagainst a seat 105 formed by the upper surface of the base 72 (FIG. 10).The gasket 103 extends around the flow directing channels 109, 111, and113.

As shown in FIG. 10, first locating elements, illustratively locatingpegs 106 a and 106 b, are positioned on the bottom of the valve assembly100 and extend downwardly from the lower surface 102. The pegs 106 a and106 b are configured to be received within second locating elements,illustratively recesses 108 a and 108 b, formed within the upper surface80 of the base 72. The position of the pegs 106 within the recesses 108facilitates proper orientation of the valve assembly 100 relative to themolded waterway assembly 70 and hence, alignment with the tubes 28, 30,and 66 and respective openings 74, 76, and 78, with appropriate ports116, 118, and 120 of the valve assembly 100. Engagement between the pegs106 and the recesses 108 may also improve resistance to torque generatedbetween the valve assembly 100 and the base 72.

As shown in FIGS. 9 and 10, the valve assembly 100 illustrativelyincludes a stem 112 that may be actuated by a handle 114 to selectivelyallow variable temperature and flow rate of water to be supplied to anoutlet port 120 from a hot water inlet port 116 and a cold water inletport 118. The base 72 of the waterway assembly 70 fluidly couples thehot water inlet port 116 to the hot water inlet tube 28, and fluidlycouples the cold water inlet port 118 to the cold water inlet tube 30.The base 72 also fluidly couples the outlet port 120 to the outlet tube66.

With further reference to FIG. 9, the valve assembly 100 illustrativelyincludes an upper housing 126, a stem assembly 128, a coupling member130, a carrier 132, an upper disc 138, a lower disc 144, a seal 150, anda lower housing 152. The stem assembly 128 illustratively includes aball 160 molded from a thermoplastic material over a portion of the stem112. A longitudinal extension or knuckle 162 extends downwardly from theball 160. The ball 160 transmits motion of the stem 112 to the upperdisc 138 through the extension 162 and the carrier 132.

The upper disc 138 is positioned on top of the lower disc 144 to controlthe mixing of hot and cold water and the flow rate of water through thevalve assembly 100. Illustratively, both the upper and lower discs 138and 144 are constructed of a ceramic material, however, any suitablematerial may be used, such as stainless steel.

In a further illustrative embodiment, a temperature limiting member 164is received intermediate the coupling member 130 and the upper housing126. The temperature limiting member 164 limits lateral pivotingmovement of the stem 112 and the extension 162, and hence the maximumallowable temperature of water flowing through the valve assembly 100.

Additional details of an illustrative valve assembly are provided inU.S. patent application Ser. No. 11/494,889, filed Jul. 28, 2006, thedisclosure of which is expressly incorporated by reference herein. Whilethe illustrative valve assembly 100 is of a movable disc variety, itshould be appreciated that other types of valve assemblies may besubstituted therefor. For example, a ball-type mixing valve assembly mayfind equal applicability with the present invention. Illustrativeball-type valve assemblies are detailed in U.S. Pat. No. 4,838,304 toKnapp, U.S. Pat. No. 5,615,709 to Knapp, U.S. Pat. No. 5,927,333 toGrassberger, and U.S. Pat. No. 6,920,899 to Haenlein et al., thedisclosures of which are expressly incorporated by reference herein.

As shown in FIGS. 5 and 6, an upper housing or escutcheon 170 includeswing portions 172 and 174 which are received over the holder 42 andsecured thereto through conventional fasteners. More particularly, hexbolts 176 and 178 are illustratively received within legs 44 and 46 andextend through apertures 180 and 182 formed in the supports 52 and 54and up into threaded apertures 184 and 186 formed in the bottom of thewings 172 and 174. The valve assembly 100, the base 72, and the holder42 are all received within a hub 187 of the escutcheon 170.

With reference to FIGS. 5 and 8, a spout 188 is formed by an upper spoutmember 189 of the escutcheon 170 and a lower spout or undercover member190. The undercover member 190 is illustratively coupled to the upperspout member 189 through resilient snap fingers 191. A boss 192 having acentral opening 193 on the undercover member 190 may be aligned with acooperating opening 194 formed in a boss 196 of the holder 42. Afastener (not shown) may be received within the aligned openings 193 and194 to further secure the undercover member 190 to the holder 42 (FIG.8).

The undercover member 190 illustratively includes a channel 198 whichreceives a portion of the outlet tube 66. The channel 198 extends fromthe hub 187 of the escutcheon 170 to an outlet 199 of the spout 188. Theoutlet tube 66 rests in channel 198 when the spout 188 is assembled.More particularly, upper spout member 189 conceals the channel 198 fromthe view of an outside observer.

In one illustrative embodiment, the spout 188 is formed of anon-metallic material. More particularly, the upper spout member 189 andthe undercover member 190 may be molded from a polymer, such as athermoplastic or a cross-linkable material, and illustratively across-linkable polyethylene (PEX). Further illustrative non-metallicmaterials include polybutylene terephthalate (PBT) and thermosets, suchas polyesters, melamine, melamine urea, melamine phenolic, and phenolic.Of course, the spout 188 may be formed of traditional metallicmaterials, such as zinc or brass. Additional details of a furtherillustrative embodiment spout is disclosed in U.S. Pat. No. 7,717,133,issued May 18, 2010, entitled “SPOUT TIP ATTACHMENT,” the disclosure ofwhich is expressly incorporated by reference herein.

As detailed herein, a first end 84 of the outlet tube 66 is coupled tothe base 72 of the waterway assembly 70. The second end 92 of the outlettube 66 is illustratively coupled to an overmold component 200. Theovermold component 200 provides an interface including a sealing surfaceand is operably coupled to an aerator assembly 202 (FIG. 8). Additionaldetails concerning the overmold component 200 are provided in U.S. Pat.No. 7,748,409, issued Jul. 6, 2010, entitled “OVERMOLD INTERFACE FORFLUID CARRYING SYSTEM,” the disclosure of which is expresslyincorporated by reference herein.

With reference to FIGS. 5 and 9, a locking sleeve or nut 204 is receivedover the valve assembly 100 and waterway base 72, and threadably engageswith the external threads 60 of the holder 42. As shown in FIG. 9, lip205 of locking sleeve 204 forces the valve assembly 100 toward the base72 of the waterway assembly 70, thereby compressing the gasket 103 foreffecting a seal therebetween.

Referring now to FIGS. 5, 6 and 9, a guide ring 206 is concentricallyreceived over the locking sleeve 204. The guide ring 206 includes aresilient body 208 having a slit 210 formed therein. A plurality ofretaining tabs 212 extend upwardly from the body 208. The retaining tabs212 of the guide ring 206 are configured to frictionally engage with aninside surface 214 of a bonnet 216 to retain the bonnet 216 in a fixedposition relative to the locking sleeve 204.

Referring now to FIGS. 15 and 16, a further illustrative embodimentfaucet 310 is shown. The faucet 310 includes many of the same featuresidentified above with respect to faucet 10. As such, similar componentsare identified with like reference numbers.

The faucet 310 includes a holder 312 having a cylindrical outer wall 314supporting a stand 316. A securing member, illustratively a conduit 318having external threads 320, extends downwardly from the holder 312. Anut 322 and washer 324 may threadably engage the threads 320 of theconduit 318 for securing the holder 312 to the sink deck 12. The stand316 includes a plurality of external threads 60 and a platform 62surrounding a longitudinal opening 64.

The holder 312 may be overmolded to an upper end 325 of the conduit 318.Alternatively, the holder 312 may be secured to the conduit 318 in otherconventional manners, such as locking rings or threads. Illustratively,the holder 312 is formed from a polymer, such as Celstran®.

The holder 312 is received within an upper housing or escutcheon 326,illustratively formed of brass. The housing 326 includes a hub 328 and aspout portion 330. As shown in FIG. 13, the spout portion 330 isconfigured to slidably receive a conventional pull out wand 332.Illustratively, the pull out wand 332 is Model No. 473 available fromDelta Faucet Company of Indianapolis, Ind. The pull out wand 332includes a coupling portion 334 configured to be received within thespout portion 330, a body 336 connected to the coupling portion 334, anda spray head 338. The second end of the outlet tube 66 illustrativelyincludes an overmolded coupling 339 which is configured to be fluidlycoupled to the wand 332. The overmolded coupling 339 illustrativelyincludes annular grooves 341 configured to receive sealing members, suchas o-rings (not shown). The coupling 339 may be formed in a mannersimilar to couplings 96 detailed above. A button 340 may be provided onthe wand 332 and is operably coupled to a diverter (not shown) to togglebetween different modes of operation, such as a spray mode and a streammode.

The molded waterway 70′ is supported by the holder 312 and includestubes 28, 30, and 66 overmolded to a base 72′, in a manner similar tothe molded waterway assembly 70 detailed above. The inlet tubes 28 and30 are configured to extend through a lower opening 342 defined by thewall 314 of the stand. The outlet tube 66 is configured to extendthrough a side opening 344 formed within the wall 314 and to the outlet346 of the spout portion 330.

As shown in FIGS. 16, 20, and 23, a first registration element,illustratively a plurality of aligned ribs 347 extend downwardly fromthe lower surface 82 of the base 72′. The ribs 347 are configured to bereceived within a second registration element, illustratively a notch349 formed within the stand 316 to facilitate proper orientation of thewaterway assembly 70′ relative to the holder 312 (FIG. 16). It should beappreciated that the base 72′ may be registered relative to the stand316 in a number of ways, including by providing the base 72′ with anasymmetrical shape configured to cooperate with mating elements on thestand 316.

The valve assembly 100 is sealingly coupled to the base in a mannerdetailed above with respect to the faucet 10. A bonnet 348 is receivedover the valve assembly 100 and the molded waterway assembly 70′. Thebonnet 348 threadably engages the external threads 60 of the holder 312.An annular lip 350 of the bonnet 348 engages the valve assembly 100,thereby securing the valve assembly 100 and the waterway assembly 70 tothe holder 312 (FIG. 17).

With reference now to FIGS. 24-26, various illustrative embodiments ofwaterway assembly 70 and cooperating flow directing member,illustratively valve assembly 100, are shown. In FIG. 24, the base 72defines hot water inlet opening 74, cold water inlet opening 76, andoutlet opening 78. Fluid passageways are defined by the inlet openings74 and 76, cooperating valve assembly 100, and outlet opening 78. Hotand cold water travels in parallel directions (as shown by arrows 352 aand 352 b) through the inlet openings 74 and 76. Valve assembly 100changes the water flow direction and redirects the mixed water flow in asecond direction downwardly through the outlet opening 78 (as shown byarrow 354).

With further reference to FIG. 25, a further illustrative waterwayassembly 70 is shown with two separate bases 72 a and 72 b. The separatebases 72 a and 72 b may be utilized for a widespread-type faucet. Moreparticularly, hot water 352 a enters through hot water inlet opening 74formed within base 72 a where it is redirected through a flow directingmember, illustratively a hot water control valve 100. The redirected hotwater passes in a second direction downwardly (as shown by arrow 354 a)and out through hot water outlet 358 a to a delivery spout (as shown byarrow 356). Similarly, cold water enters through cold water inletopening 76 and is redirected by a cold water outlet valve 100 b. Theredirected cold water then exits the base 72 b through cold water outlet358 b in a second direction to the delivery spout. As shown, the coldwater combines with the hot water prior to exiting the delivery spout.

FIG. 26 illustrates yet another illustrative embodiment waterwayassembly wherein first and second bases 72 a′ and 72 b′ are provided fora centerset-type faucet. The inlet openings 74 and 76 are similar tothose identified above with respect to FIG. 25. Similarly, hot and coldwater valves 100 a and 100 b are provided to control the flow of fluidthrough the respective inlets 74 and 76 to hot and cold water outlets358 a′ and 358 b′, respectively. The hot and cold water outlets 358 a′and 358 b′ in FIG. 26 each include first and second portions 360 a, 360b and 362 a, 362 b, respectively, disposed at right angles to eachother. More particularly, fluid flow in a first direction (as shown byrespective arrows 352 a, 352 b) is redirected from the inlet 74, 76 tooutlet 358 a′, 358 b′ for exiting base 72 a′, 72 b′ in a seconddirection (as shown by arrow 362 a, 362 b) which is substantiallyperpendicular to the first direction. The fluid flow from the outlets358 a′ and 358 b′ then combines and passes to the outlet of a deliveryspout (as shown by arrow 366).

Although the invention has been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe spirit and scope of the invention as described and defined in thefollowing claims.

The invention claimed is:
 1. A fluid delivery device comprising: a valveassembly including a lower surface and a first locating elementsupported by the lower surface; and a waterway assembly including afirst fluid transport component having opposing first and second ends, asecond fluid transport component having opposing first and second ends,and a base having an upper surface and a lower surface, the base beingovermolded around the first end of the first fluid transport componentand the first end of the second fluid transport component, the waterwayassembly further including a second locating element supported by theupper surface of the base and configured to cooperate with the firstlocating element of the valve assembly to facilitate proper orientationof the valve assembly relative to the waterway assembly.
 2. The fluiddelivery device of claim 1, further comprising a holder supporting thebase of the waterway assembly.
 3. The fluid delivery device of claim 2,wherein the holder includes a body and a securing member extendingdownwardly from the body and configured to secure to a sink deck.
 4. Thefluid delivery device of claim 2, further comprising a firstregistration element supported by the base, and a second registrationelement supported by the holder and configured to cooperate with thefirst registration element to facilitate proper orientation of thewaterway assembly relative to the holder.
 5. The fluid delivery deviceof claim 1, wherein the base of the waterway assembly is formed of apolymer.
 6. The fluid delivery device of claim 5, wherein the firstfluid transport component, the second fluid transport component, and thebase are formed of a cross-linkable polymer.
 7. The fluid deliverydevice of claim 6, wherein the first fluid transport component, thesecond fluid transport component, and the base are formed ofpolyethylene which is cross-linked as an assembly.
 8. The fluid deliverydevice of claim 5, wherein the first fluid transport component, thesecond fluid transport component, and the base are formed of a raisedtemperature resistant polyethylene.
 9. The fluid delivery device ofclaim 1, further comprising fluid couplings overmolded at the secondends of the first and second fluid transport components.
 10. The fluiddelivery device of claim 1, further comprising a locking member operablycoupled to the valve assembly and configured to secure the valveassembly to the waterway assembly.
 11. The fluid delivery device ofclaim 1, further comprising an upper housing formed of a non-metallicmaterial and including a spout having an outlet fluidly coupled to thesecond fluid transport component, and a channel to receive the secondfluid transport component.
 12. The fluid delivery device of claim 1,further comprising a first flow directing channel extending into theupper surface of the base and in fluid communication with the firstfluid transport component, and a second flow directing channel extendinginto the upper surface of the base and in fluid communication with thesecond fluid transport component.